Method of making wheel covers



Feb. 21, 1961 G. A. LYON METHOD OF MAKING WHEEL COVERS 5 Sheets-Sheet 1 Filed Aug. 13, 1953 619a i fz Zyw it g5 if? /4 1, mMmTM/BTWA Feb. 21, 1961 G. A. LYON METHOD OF MAKING WHEEL covans Filed Aug. 15, 1953 3 Sheets-Sheet 2 a o/ye A Zyazz Feb. 21, 1961 G. A. LYON METHOD OF MAKING WHEEL COVERS 3 Sheet 3 Filed Aug. 13, 1953 United States Patent METHOD OF MAKING WHEEL COVERS George Albert Lyon, 13881 W. Chicago Blvd., 7 Detroit, Mich.

Filed Aug. 13, 1953, Ser. No. 374,076

2 Claims. (Cl. 113-51) The present invention relates to a novel method of making wheel covers of the type adapted to be applied in ornamental and protective covering relation to the outer sides of vehicle wheels.

An important object of the present invention is to provide a novel method of making wheel covers from sheet metal.

Another object of the invention is to provide a novel method of making wheel covers from sheet metal and providing the covers with integral struck-out self-retaining wheel-engaging fingers.

A further object of the invention is to provide a novel method of making wheel covers from sheet metal with retaining fingers struck from an intermediate portion of the cover structure to provide air circulation openings through the cover and self-retaining fingers from the material struck out in providing the air circulation openings and with such fingers shaped to afford substantial stiffness and resilience in the fingers.

Other objects, features and advantages of the present invention will be readily apparent from the following detailed description of a preferred embodiment thereof taken in conjunction with the accompanying drawings in which:

Figure 1 is a radial sectional view through a wheel cover after it has been partially completed from sheet metal, taken substantially on the line II of Figure 2;

Figure 2 is a fragmentary more or less segmental outer face elevational view of the partially completed wheel cover of Figure 1;

Figure 3 is a fragmentary radial sectional view through the partially completed wheel cover of Figure 1 and punch and die apparatus for striking out the retaining finger tabs or extensions and at the same time providing air circulation openings through the cover;

Figure 4 is a similar fragmentary radial sectional view through the partially formed cover and apparatus for bending the struck-out finger tabs into oblique position;

Figure 5 is a similar radial sectional view through the partially formed cover and through apparatus for cold working and shaping the retaining finger tabs or extensions; v

Figure 6 is a radial sectional view similar to Figure 5 but showing the relationship of the apparatus upon completion of the retaining finger;

Figure 7 is a fragmentary top plan view of the core die structure of the apparatus of Figures 5 and 6 about which the retaining fingers are cold worked and shaped;

and

Figure 8 is a fragmentary radial sectional view through the finished wheel cover and a vehicle wheel to which the cover may be applied.

In making a wheel cover 10 according to the present invention, a sheet metal blank such as stainless steel, brass, or the like of suitable alloy to provide the requisite working characteristics and service requirement characteristics, is shaped by any suitable drawing, spinning or combination shaping operations. This provides a cirice ing annular channel juncture 14 with a generally radiallyand axially outwardly directed outer marginal portion 15 which in the present instance is preferably of concave convex large radius rib-like shape. At suitable spaced intervals, the intermediate generally dished portion 13 is provided with depressed preferably generally keystone shaped areas 17 with the wider or head end portions of the depressions at the radially outer sides thereof and extending across the juncture rib 14. .At the convergent sides and radially inner ends, the depressed areas 17 are defined by a generally axially inwardly. directed continuous flange 18.

It will be appreciated that in working of the sheet metal blank into the contour of Figure 1 wherein the generally dished portion 13, 14 is formed there is a substantial working of the material of the annular dished portion. The further working to which the depressed portions 17 are subjected additionally work hardens in such areas beyond the work hardening incident to dishing of the portion 13. This is a result of stretching of the material of the depressed portions 17 incident to the depressing thereof below the contour of the dished portion 13.

According to the present invention, the depressed sub- 'stantially work hardened areas 17 of the cover blank are struck out to provide retaining fingers for the cover and to provide air circulation openings through the cover while leaving the respective flanges 18 as reinforcement about the remainder of the openings left by the striking out of the depressed areas. To this end, the cover 10 is placed in a punch and die mechanism 19 (Figure 3) comprising a lower female die member 20 having the upper surface thereof contoured complementary to the inner surface of the intermediate and annular outer portions 13 and 15 of the cover to receive the same snugly.

Complementary depressions 21 in the upper contoured die member 20 and engageable with the radially outer marginal portion 15 of the cover blank on the die member is a hold down die ring 23 having a lower holding surface complementary to the outer convex surface of the cover marginal portion. After the cover blank has been positioned upon the die member 20, the hold down ring is moved into clamping engagement to the outer annular cover portion 15.

After the cover blank has been clamped in position on the die member 20, a relatively reciprocable ring-shaped member 24 reciprocably guided by the hold down ring 23 is driven toward the clamped cover to punch out the depressed areas 17 of the cover by means of depending respective punches 25 which register with the openings 22 and the'female die member 20. For this purpose,

v the upper edges'defining the punch holes 22 at the bottoms of the respective depressions 21 provide shearing edges except at the radially outer sides of the openings 22 which merge smoothly with the contoured convex surface complementary to and supporting the outer marginal portion 15 of the cover'member. A clearance equal to approximately thickness of the material is afforded between the radially outer face of the respective em-set Iii punches 25 and the radially'outer"surfaoes'defining the respective openings 22. Accordingly, as the punches 25 are driven down into the openings 22, the depressed areas 17 of the covenblahk areet ck'out and severed from the flange 18 butrer'nain c'o'ntiniio'u's inbne'piece as axially inwardly directed extensions from the inner margin of the radially outer portion 'of the cover.

By having the tip portions of the punches "provided with a nose contoured complementary to the radius of the juncture groove 14 in that portionof the punch that drives down into the'grQoVeQasshoVvnat 27, a smooth working rounded shoulder is provided which acts upon the punched out tongue-like extension 17 to work the same from theoblique radially inwardly and "axially outwardly directed position thereof in the unsevered condition into the axially inwardly elongated condition thereof at the completion of the punchirig and straightening stroke of the -punchdie member 24, It will be obs'erv ed that the length of the punch manner 25 fis'preferably as long as the elongated tongue or fin er '17"at completion ofthe axial elongation thereof.

Afterrernoval of the cover member ldfro m the die as srriebl'y 19, it is placed into and work e'd u'pon in a die assembly'28 wherein the finger extension tongues or tabs 17 are further engaged a nd bent toward final shape and as thus worked are additionally hardened for stifiened resiliency. To this end, the die assembly 28 comprises a base member 29 of preferably annular shape upon which the cover member 119 is placed in inverted position with the outer surfaces of the intermediate cover portion 13 and the outer anular portion 15 engaging complementary annular upper'surfaces of the lower member An annular upper shaping ring 30 is then driven toward the lower supporting ring 29so that an oblique generally axially and radially inwardly directed working surface 31 thereof will engage and prograssively bend the finger tab extensions 17 into oblique generally radially outward direction as viewed in Figure 4.

After release from the die assembly 28, the cover member 1 0'is placed into a fin'al finger tab forming die a'ssrnebly 32 (Figures 5 and 6). The latter die mechanism comprises a base member 33 supporting a reciprocable yieldably mounted cover supporting and retaining finger forming die member 34. Coiled compression springs 35 normally urge the die ring 34 upwardly about a central guide boss 37 into engagement with a stop plate 38. 'I'hereby, anupper annular forming and supporting nose or ridge 39 on the die ring 34 is normally supported by the springs 35 in a position to receive the cover'meinber 10 adjacent to juncture of the finger tab extensions 17 with the reinforcing flange 1 8 and with'the distal end portions of the retaining finger extensions '17 clearing a formingrib 40 on'an upstanding annular portion 41 of the base member 33 disposed in fixed relation'at theradially outer side of the die ring 34. It will be observed that the rib 40-has a generally radially out wardly and downwardly axially oblique radially outer surface 43 which is disposed at approximately the same oblique angle as the inner faces of the obliquely disposed finger extensions 17.

cooperatively related to the forming ridge or rib 40 'is a series" of retaining finger core block elements 44 carried fixedly by an annular ring die member 45 supported yieldably by compression springs 47 in normally elevated relation above the base member 33 as guided by the annular upstanding portion 41 and with the core elements 44 disposed in spaced relation above the forming ridge 40. In the upwardly extended relation of the member 45, the core elements 44 have depending nose portions 48 disposed in'clearance relation to the radially outer side of the supporting and'forming ridge or rib 39 so that the cover it can be manipulated into position by extending the radially outwardly angled retaining finger tab extensions 17 into the clearance spaces between the core elements 44 (Figure 7) until the outer annular cover portion comes to rest upon the complementary contoured upper faces of the core elements 44. The cover member 10 is then given a turning movement relative to the die structure 32 to register the nose portions 48 of the core members behind the retaining finger tab extensions 17, the radially inner surface of the nose 4-8 being complementary in shape, in each instance, to the portion of the retainingfin'ger tab extensions 17 adjacent to juncture thereof with the annular outer cover portion 15 and the reinforcing flange '18.

Then, a clamping and pressure ring 49 is driven into clamping engagement with the'upper face of the outer annular cover portion 15 to Which it is complementary, to clamp the cover to the core elements 44 as seen in Figure 5. As pressure is thus applied, the proximal portions of the finger extensions 17 are clamped between the nose portions 48 of the core elements and the supporting and forming ridge 39. p V q Final shaping 'of the'retaining fingers is accomplished by depressing the ring die members 45 and 34 by means of the pressure ring 49 to effect turning of th'e di stal portions of the finger extensions 17 about the radially offset complementary forming rib 40 and the core element nose portions 48. To this end, the radially inner side of the forming rib 40 and the radially outer "side 'andtip surfaces of the nose "48 are of complementary shape and obliquely angled generally axially and radially outwardly. Therefore, as the core element nose portions '48 are driven down alongside'the radially inner side of the rib 40, the retaining finger extensions 17 are 'turnedand each worked progressively into generally axially outwardly and radially outwardly biased or oblique direction as shown in Figure '6. v v I In the final'pha'se of the shaping stroke" of the die structure, wherein the finger extensions are fully shaped and clamped between the die nose elements 48 and'the rib 4% the distal terminal extremity portions of the finger extensions are bent generally radially outwardly within a reentrant radi-used forming surface 50 provided for this purpose at'the juncture of the radially outer sides of the forming noses 48 with the body portions of the core elements 44. Thereby the finger extensions 17 are now provided with body portions 174 joining the cover, resilient leg portions 17b angled generally in reverse from the body portions, and short and stiff generally radially outwardly directed cover engaging terminal flanges 170.

It will be observed that through appropriate shaping of the dies, the clip or'finger body portions 17a, at least are transversely bowed and thus stiffened. Because of the'original keystone shape of the finger tabs, the fingers 17 are tapered from their proximal to their distal ends.

Following the finger shaping operation, the die assembly 32 is opened by retracting the pressure ring 49 away from the cover so that the'springs 35 and 47 can lift the die rings 34 and 45, respectivley, to clear the formed fingers above the forming ridge '40. Then the cover is given sufiicient turning movement to clear the formed retaining fingers 17 from the core members 44'and the cover is lifted away from the lower die mechanism of the die assembly 32. q

As a final cover shaping operation, the extremity edge portion of the outer annular cover section 15 'is preferably turned under to provide a reinforcing and finishing flange 51 (Figure 8). At this time, also, further finishing of the cover may be accomplished if desired, although it will be appreciated that where the cover is to be polished or plated and polished or burnished, that is best accomplished after shaping of the cover as shown in Figure 1 and before the finger extensions are punched therefrom and shaped.

The finished cover is adapted to 'be appliedto a vehicle wheel such as shown-in Figure 8 including a disk wheel body or spider 52 joined to a multi-fiange tire rim 53 and providing at juncture with the tire rim a plurality of Wheel openings 54 through which air may circulate inthe operation of the wheel for cooling a brake drum (not shown) of the vehicle axle to which the wheel may be attached. The tire rim includes an outer side flange 55, an intermediate generally radially and axially outwardly oblique flange 57 and a terminal flange 58, the flanges being related to support a pneumatic tire and tube assembly 59.

The retaining fingers 17 engage the tire rim for retaining the cover on the wheel. To this end, the cover is adapted to be pressed axially inwardly so that the retaining finger tips 170 cam into retaining gripping engagement with the inner face of the intermediate flange 57 and stress the finger portions 17b radially inwardly to afford radially outward thrusting pressure for the retaining tips of the finger terminals 170 against the intermediate flange of the tire rim. relation of the cover the shoulder at juncture of the body and flexible finger portions of the fingers 17 engages at the juncture groove between the side flange 55 and the intermediate flange 57, thereby retaining the cover in spaced relation to the wheel body and tire rim portions of the wheel and holding the cover centered on the wheel. Since the outer portion as well as the turned edge portion 51 of the cover is held spaced from the tire rim, air circulation may proceed between the tire rim and such outer portion. Furthermore, the openings defined within the reinforcing flange 18 where the retaining fingers have been struck from the cover aflord circulation openings generally registering with or opposite the wheel openings 54.

It will be understood that modifications and variations may be effected without departing from the scope of the novel concepts of the present invention.

I claim as my invention:

1. In a method of making a wheel cover from sheet metal, shaping a sheet metal blank into a circular member having a generally radially extending annular portion spaced substantially radially inwardly from the periphery of the cover, working a plurality of circumferentially spaced depressed areas into said annular portion and with a short generally axially extending flange connecting the respective depressed areas to the remainder of said annular portion and resulting in work hardening of such areas, striking out said depressed areas within said flange and attached to the cover member integrally in one piece at the radial side of each of the struck out In the final assembled.

depressed areas while leaving the respective flange as a reinforcmeent about the remainder of the opening left by the striking out of the depressed area, and progressively working and further hardening the struck-out areas to provide return-bent retaining finger extensions for retaining engagement with a portion of a wheel to which the cover is thereby adapted to be attached.

2. In a method of making a Wheel cover from sheet metal, shaping a sheet metal blank into a circular member and in the shaping working a dished annular portion spaced radially inwardly from the periphery of the cover, Working a plurality of circumferentially spaced depressed areas into said dished portion and with a short generally axially extending flange connecting the respective depressed areas to the remainder of said dished portion and resulting in further working and hardening of such areas, striking out said depressed areas within said flange and attached to the cover member integrally in one piece at the radial side of each of the struck-out depressed areas, while leaving the respective flange as a reinforcement about the remainder of the opening left by the striking out of the depressed area, and bendably working and further hardening the struck-out areas to provide angular retaining finger extensions for retaining engagement with a portion of a wheel to which the cover is thereby adapted to be attached.

References Cited in the file of this patent UNITED STATES PATENTS 307,357 Tweddell Oct. 28, 1884 518,766 Plecker' Apr. 24, 1894 1,044,283 Stanger Nov. 12, 1912 2,094,326 Lyon Sept. 28, 1937 2,198,056 Lyon Apr. 23, 1940 2,240,294 Greif Apr. 29, 1941 2,368,235 Lyon Jan. 30, 1945 2,368,238 Lyon Jan. 30, 1945 2,386,223 Lyon Oct. 9, 1945 2,597,010 Lyon May 20, 1952 2,607,633 Lyon Aug. 19, 1952 2,675,271 Lyon Apr. 13, 1954 2,683,632 Lyon July 13, 1954 FOREIGN PATENTS 486,487 Canada Sept. 16, 1952 

